Support structure

ABSTRACT

A support structure is configured to provide support and structure for a fabric cap assembly. The support structure includes a lower band portion shaped to accommodate a lower inner surface of the fabric cap assembly and at least one support arch extending from the lower band portion and comprising a concave shape.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 63/236,183, filed on Aug. 23, 2021, which is hereby incorporated by reference for all purposes as if fully set forth herein.

BACKGROUND

Head coverings with protective eye shading bills, typically called baseball caps, are worn by men, women, and children all over the world. These hats, or caps, provide comfort for the user by preventing sun glare to the eyes and protection of the scalp or hair from sun related damage or burning. Over many industries and in many various markets, these caps are utilized for team identification, for marketing products, for advertising products, for company logo promotion, and the like.

In many instances, the fabric utilized to construct the cap is selected based upon the fabrics ability to retain the coloring dye used to colorize the fabric and upon final product costing. As these caps are available from many different manufacturers, from many different countries, cost competitiveness is paramount, and fabrics used must support the overall competitive unit cost. As a result, in most every cap, the fabric will tend to lose its stiffness with a day or two of use by the end-user.

The sun shading bill portion of a cap may be constructed with a stiff inner member to retain its shade casting ability, but the portion of the cap which covers the head may typically soften with use. While a softer fabric tends to provide some additional comfort when in contact with the skin, the portion of the cap at the front, just above the sun shading bill portion, may become loose and droops or falls downward onto the wearer's forehead.

Once the front portion has softened and collapsed, any logo, advertising, or messaging imprinted or embroidered thereon may become more difficult to read or to see, defeating the purpose of the messaging on the cap. For some users, there is a desire for their cap to retain its original shape and purpose. For some advertisers, using the caps for marketing, there is a desire for their messaging to look good for as long as possible.

The above information disclosed in this Background section is only for enhancement of understanding of the background of the inventive concept, and, therefore, it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the inventive concept, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the inventive concept, and, together with the description, serve to explain principles of the inventive concept.

FIG. 1 is an isometric view of a support structure according to an exemplary embodiment.

FIG. 2 is a front view of the support structure of FIG. 1 .

FIG. 3 is a top view of the support structure of FIG. 1 .

FIG. 4 is a left side view of the support structure of FIG. 1 .

FIG. 5 is a bottom view of the support structure of FIG. 1 .

FIG. 6 is a back view of the support structure of FIG. 1 .

FIG. 7 is a back isometric view of the support structure of FIG. 1 .

FIG. 8A is a front isometric view of the support structure of FIG. 1 having a detailed area “A”.

FIG. 8B is a front isometric view showing the detailed area “A” of FIG. 8A.

FIG. 9A is a top view of the support structure of FIG. 1 having a cross-sectional line “A-A′”.

FIG. 9B is a cross-sectional view of the support structure of FIG. 9A taken along line “A-A′” and having a detailed area “B”.

FIG. 9C is a cross-sectional view showing the detailed area “B” of FIG. 9B.

FIG. 10 is an isometric view of a support structure according to an exemplary embodiment.

FIG. 11 is a front view of the support structure of FIG. 10 .

FIG. 12 is a top view of the support structure of FIG. 10 .

FIG. 13 is a left side view of the support structure of FIG. 10 .

FIG. 14 is a bottom view of the support structure of FIG. 10 .

FIG. 15 is a back view of the support structure of FIG. 10 .

FIG. 16 is a back isometric view of the support structure of FIG. 10 .

FIG. 17 is an isometric view of the support structure of FIG. 10 , showing clips as detached from the support structure and ready to be installed over the support structure according to an exemplary embodiment.

FIG. 18 is an isometric view of the support structure of FIG. 10 , showing clips as installed over the support structure according to the exemplary embodiment of FIG. 17 .

FIG. 19 is an isometric view of a clip according to an exemplary embodiment.

FIG. 20 is a right side view of the clip of FIG. 19 .

FIG. 21 is a back view of the clip of FIG. 19 .

FIG. 22 is a bottom view of the clip of FIG. 19 .

FIG. 23 is a side perspective view of the clip of FIG. 19 .

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of various exemplary embodiments. It is apparent, however, that various exemplary embodiments may be practiced without these specific details or with one or more equivalent arrangements.

The terminology used herein is for the purpose of describing particular embodiments and is not intended to be limiting. As used herein, the singular forms, “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Moreover, the terms “comprises,” comprising,” “includes,” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components, and/or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure is a part. Terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense, unless expressly so defined herein.

According to exemplary embodiments, a unitary formed support structure is provided with a geometry shaped to provide long term support for the fabric display surface of a cloth cap. The unitary support structure assists in retaining the original shape of a cloth cap and permits the front-center portion of the cap to resist the tendency to collapse inward and downward with use, thereby preserving the ability for a displayed message to be seen clearly for an extended duration of use. The unitary formed structure may be comprised of a polymeric material and formed by an injection molding process for net shape manufacture with no secondary operations required. Surfaces for imprinting are provided allowing the unitary formed structure to be customized for branding or other marketing purposes. Integrated features are provided to grab onto the inner fabric surface of the cap for long term retention of the unitary formed structure within the cap assembly.

Referring to FIG. 1 , FIG. 2 , FIG. 3 , FIG. 4 , FIG. 5 , FIG. 6 , FIG. 7 , FIG. 8A, FIG. 8B, FIG. 9A, FIG. 9B, and FIG. 9C there is shown an exemplary example of a unitary support structure 100 adapted for use within a cap fabricated from a woven cloth material, or the like.

The unitary support structure 100 has formed thereon a lower band portion 110 shaped to accommodate the lower inner surface of the cap which fits around a wearer's head.

Most cloth cap assemblies have situated at a lower surface an inner band, which is folded upward from the base of the cap along the inner perimeter of the cap. This inner band is sometimes referred to as a “sweat band” but in fact it serves as the cap's primary contact point with the wearer's head. This double layer of fabric acts to soften the squeeze of the cap when worn as felt by the wearer's head. The lower band portion 110 of unitary support structure 100 is shaped and sized to fit between the inner surface of the cap fabric and the folded inner surface of the “sweat band” portion of the cap assembly. As such, the lower band portion 110 is formed as thin as possible so as not to be felt by the user through the “sweat band” covering.

Wall thickness reductions 120 are provided around the lower band portion 110 to provide a thinner cross-section of injection molded material, resulting in the unitary support structure 100 being easier to bend and flex. This ability to bend and flex is important due to variations in potential user head size. The lower band portion 110 is adapted to substantially extend from the front-center of the cap to approximately the wearer's temple on each side of the head. At this temple location the skull forehead bone ceases resulting in a slight depression of the head. The selection to change the overall thickness of the cap band by the cessation of the lower band portion 110 at this non-bone location helps to reduce the wearer's ability to notice, or feel, the presence of the unitary support structure 100 during use. The terminal ends of the lower band portion 110 have a curved lower surface 112 which is useful during installation of unitary support structure 100 into the “sweat band” of a fabric cap assembly.

Standing upright above the lower band portion 110 are three support arches: a center support arch 130; a right support arch 140; and a left support arch 150. These support arches are shaped with a gentle inward spherical form to provide a stiffening geometry to each support arch feature. Openings in each support arch, center support arch opening 132, right support arch opening 142, and left support arch opening 152, provide areas for air circulation in the unitary support structure 100 to assist in the prevention of moisture retention within the cap.

Two sharp “V”-shaped recesses 160 and 160′ are formed between the center support arch 130 and the right support arch 140 and the left support arch 150, respectively. The “V”-shaped recesses 160 and 160′ allow the support arches to rotate inward when the wearer's head is small, or to rotate outward when the user's head is large, and allow the support arches to flex inward under the pressure of the inner surface of the fabric comprising the cap. The support arch geometry used provides stiffness, strength, and helps to shape the cap display surface fabric.

Fabric grab points are formed on the outer surfaces of lower band portion 110 and on each of the center support arch 130, right support arch 140, and left support arch 150 to pierce or “bite” into the cap fabric once the unitary support structure 100 is installed into a cloth cap assembly. Lower fabric grab points 116 are positioned at intervals around the lower band portion 110 for optimum engagement with the cap fabric when installed. Lower fabric grab points 116 are formed to pierce the fabric to engage and hold the support structure 100 in position, but are also adapted with a recess 118 to allow a portion of each fabric grab point 116 to fold inward under pressure when the cap is worn tightly around the skull of the wearer, preventing unwanted pressure on the wearer's forehead during use.

Upper fabric grab points 136, 146, and 156 are located at the extreme top edge of the respective center support arch 130, right support arch 140, and left support arch 150. The fabric grab point features 116, 118, 136, 146 and 156 are all formed within the injection mold and are all shaped for adequate release when the mold opens, resulting in a less complex mold and a more reliable molding process.

The center support arch 130 has a bridge surface 138 at the lower portion of the center support arch opening 132, which is approximately 70% of the nominal wall thickness of the support arch feature. The bridge surface 138 provides an inner surface elevated above the lower band portion 110 that may remain uncovered by the cap assembly “sweat band” when installed into the cap. As such, when the cap is removed from the wearer's head, this uncovered portion of the bridge surface 138 is visible and can be used as a display surface.

Referring to FIG. 6 and FIG. 7 , a logo 170 is shown as molded into the lower band portion 110 that may be utilized for a display for branding of the unitary support structure 100. Also, an image (not shown) may be imprinted above the logo 170 on the bridge surface 138 of the center support arch 130 using a pad printing technique to allow customization of the unitary support structure 100, such as for team, college, or state or country identification.

A unitary support structure 200 according to an exemplary embodiment is shown in FIG. 10 , FIG. 11 , FIG. 12 , FIG. 13 , FIG. 14 , FIG. 15 , FIG. 16 , FIG. 17 , and FIG. 18 . The unitary support structure 200 may be substantially the same as the unitary support structure 100 described above with respect to FIG. 1 , FIG. 2 , FIG. 3 , FIG. 4 , FIG. 5 , FIG. 6 , FIG. 7 , FIG. 8A, FIG. 8B, FIG. 9A, FIG. 9B, and FIG. 9C of the present application, and the disclosure thereof is incorporated herein by reference, and any repeated disclosure may be omitted for the sake of brevity.

The unitary support structure 200 has a clip 280 molded onto each of the terminal ends of the lower band portion 210, thus the unitary support structure 200 and the clips 280 are formed as a unitary piece. A user may twist and break each clip 280 away from the unitary support structure 200. Each clip 280 may be used to attach the unitary support structure 200 into a cap (not shown), trapping a sweat band of the cap beneath the clip 280, to retain the unitary support structure 200 within the cap. As described in detail below with respect to FIGS. 19-23 , each clip 280 has a grip portion 281, a front prong 282, and a rear prong 283.

Guides 285 are arranged in the lower band portion 210 of the unitary support structure 200 under a right support arch 240 and a left support arch 250 thereof. Each clip 280 is configured to fit into the guides 285, as shown in at least FIG. 17 and FIG. 18 . The rear prong 283 of each clip 280 fits precisely into the guide 285 at an exterior side of the lower band portion 210 (that is, where an interior side of the lower band portion 210 would be adjacent to a user's head). The front prong 282 of the clip 280 will not fit into the guide 285 at the exterior side of the lower band portion 210, and only fits into the guide 285 at the interior side of the lower band portion 210.

In particular, each guide 285 at the exterior side of the lower band portion 210 includes a first side guide portion 286 and a second side guide portion 286′, which create a unidirectional installation means. Accordingly, only the rear prong 283 of each clip 280 fits into the guide 285 between the first side guide portion 286 and the second side guide portion 286′.

A feed-through clip 290 is arranged in the lower band portion 210 under a center support arch 230 of the unitary support structure 200. The feed-through clip 290 is molded into the unitary support structure 200 and does not need to be removed or altered for use. The sweat band of the cap is configured to be placed in front of the feed-through clip 290, but stay behind the unitary support structure 200 (i.e., the user head side) everywhere else. First slits 292 and second slits 292′ are formed in the lower band portion 210 on either side of the feed-through clip 290. Thus, the sweat band may be threaded through the first slits 292 and second slits 292′ and over the feed-through clip 290. An extension portion 294 of the clip 290 is formed on an exterior side thereof, which is configured to grab the sweat band to help retain the unitary support structure 200 within the cap.

In an alternative embodiment (not shown), three guides 285 may be formed in the lower band portion 210 of the unitary support structure 200 under a center support arch 230, the right support arch 240, and the left support arch 250. Accordingly, the user could use a combination of clips 280 in conjunction with the guides 285 under the center support arch 230, the right support arch 240, and/or the left support arch 250. In another alternative embodiment (not shown), three feed-through clips 290 may be formed in the lower band portion 210 of the unitary support structure 200 under the center support arch 230, the right support arch 240, and the left support arch 250, and clips 280 would not be provided with the unitary support structure 200.

A clip 280 according to an exemplary embodiment is shown in FIG. 19 , FIG. 20 , FIG. 21 , FIG. 22 , and FIG. 23 , and as described above with respect to FIGS. 10-18 , the clip 280 has a grip portion 281, a front prong 282, and a rear prong 283. The clip 280 may be substantially the same as the clip 280 described above, and the disclosure thereof with respect to FIGS. 10-18 is incorporated herein by reference, and the present disclosure is likewise is incorporated by reference with respect to the embodiment shown in FIGS. 10-18 . The grip portion 281 includes ribs, which function as enhanced grip features to aid a user when installing the clip 280 in the guide 285. The front prong 282 has serrated grips on the inner surface thereof, configured to assist securing the sweat band, and to improve retention of the unitary support structure 200 within the cap. A snap ledge 287 is formed on either side of the rear prong 283, forming a tongue end of the rear prong 283. The snap ledge 287 is configured to fit over a cut-out portion 288 of the guide 285, to lock the clip 280 in place in the guide 285 and retain the clip 280 to the unitary support structure 200.

Although certain exemplary embodiments and implementations have been described herein, other embodiments and modifications will be apparent from this description. Accordingly, the inventive concept is not limited to such embodiments, but rather to the broader scope of the presented claims and various obvious modifications and equivalent arrangements. 

What is claimed is:
 1. A support structure configured to provide support and structure for a fabric cap assembly, the support structure comprising: a lower band portion shaped to accommodate a lower inner surface of the fabric cap assembly; at least one support arch extending from the lower band portion and comprising a concave shape. 